Advanced Manufacturing Methods and Their Effects on Residual Stress

To meet performance requirements for next generation aircraft and rotorcraft while maintaining the current and legacy fleet, advanced alloys, product forms and manufacturing methods are essential. Processes like machining, joining, additive manufacturing, forging, rolling, and extruding produce residual stresses. If not well understood and mitigated, these residual stresses can have negative effects on performance including post-machining distortion and reductions in fatigue and corrosion performance.  Demonstration programs within the DoD have recently shown that management of residual stress can provide improvements in manufacturing throughput, cost savings, weight savings, and increased performance.  Examples of residual stress, its effects, measurement techniques, mitigation methods and benefits will be presented based on multiple platform applications.